WO2018103049A1 - 一种一体化铸造式法兰及其制造工艺 - Google Patents

一种一体化铸造式法兰及其制造工艺 Download PDF

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Publication number
WO2018103049A1
WO2018103049A1 PCT/CN2016/109078 CN2016109078W WO2018103049A1 WO 2018103049 A1 WO2018103049 A1 WO 2018103049A1 CN 2016109078 W CN2016109078 W CN 2016109078W WO 2018103049 A1 WO2018103049 A1 WO 2018103049A1
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Prior art keywords
flange
end cone
wax
transition portion
sensor
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PCT/CN2016/109078
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English (en)
French (fr)
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王树军
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王树军
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Priority to PCT/CN2016/109078 priority Critical patent/WO2018103049A1/zh
Publication of WO2018103049A1 publication Critical patent/WO2018103049A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
    • F02M35/10—Air intakes; Induction systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L23/00—Flanged joints

Definitions

  • the invention relates to the technical field of automobile parts, in particular to an integrated casting flange and a manufacturing process thereof.
  • the car engine is equipped with a flange for the valve, which is also used to mount the sensor.
  • the flange is mainly composed of a flange, an end cone and a sensor nut.
  • a flange is first produced by forging, an end cone is produced by punching, and a sensor nut is produced by machining.
  • the flange, the end cone and the sensor nut are welded together as a whole, which not only has many manufacturing processes, long working hours, high cost, waste of resources, but also the flange sealing surface after welding is easily deformed, and the flatness is above 0.5, resulting in When it is connected to the engine, it has poor sealing performance and there is a risk of air leakage, which poses a safety hazard.
  • the present invention provides the following technical solutions:
  • An integrated cast flange includes a flange, an end cone and a sensor nut; the bottom end of the end cone is provided with a transition portion, the transition portion and the end cone are an integral structure, and the end cone is fixed to the flange through the transition portion On the disc, the inner side surface of the transition portion is flush with the inner side surface of the end cone, the outer side surface of the transition portion has a circular arc shape, and the upper and lower ends of the outer side surface of the transition portion are smoothly butted with the end cone and the flange respectively;
  • the end cone is provided with a sensor mounting hole, and the sensor nut is fixed on the sensor mounting hole; the flange, the end cone and the sensor nut are integrally cast.
  • the transition portion has a thickness of 2 mm at the upper end and a thickness of 2.5 mm at the lower end of the transition portion.
  • a feeding strip is further disposed between the sensor nut and the flange, and the feeding strip is fixed on the end cone, and the upper end of the feeding strip is fixedly connected to the sensor nut, and the lower end of the feeding strip Fixedly attached to the flange.
  • the manufacturing process of the integrated cast flange is as follows:
  • Shot wax wax is obtained by spraying wax at an ambient temperature of 22-26 ° C.
  • the wax temperature is 51-55 ° C
  • the pressure is 15-25 kg/cm 2
  • the waxing time is 40 s
  • the wax is taken out and placed. Cooling in the finalizing tooling;
  • Wax inspection Check the cooled wax to check whether the wax has structural defects. If there is structural defect in the wax, return to step 1). Otherwise, proceed to the next step;
  • Sand shell The ambient temperature is 22-26 °C, and the surface layer, the first layer, the second layer, the third layer, the fourth layer and the fifth layer are sequentially coated on the outside of the wax member, and finally the sealing is performed to obtain the wax component.
  • Dewaxing The sand shell containing the wax component is placed in a dewaxing kettle, dewaxed for more than eight minutes, and an empty sand shell is obtained.
  • the temperature in the autoclave of the dewaxing kettle is 140-170 ° C, and the pressure in the autoclave is 0.7. -0.8Mpa;
  • the flange manufactured by the invention has a transition portion between the flange and the end cone, which can strengthen the connection strength between the flange and the end cone and improve the stability of the product;
  • the flange manufactured by the invention has a feeding strip between the sensor nut and the flange, and the feeding strip can strengthen the connection strength between the flange and the end cone on the one hand, and can act on the sensor nut on the other hand.
  • the feeding effect makes the joint between the sensor nut and the end cone less likely to shrink, which improves the joint strength, greatly reduces the probability of breakage and improves the service life of the product;
  • the manufacturing process of the flange of the invention eliminates the processes of forging, stamping, machining, integral welding, etc., the manufacturing process is reduced, the working time is shortened, the cost is reduced, and the resource is saved. Since the welding is not required, the flatness of the flange sealing surface is 0.2. In the following, the sealing performance when connecting with the engine is ensured, the product is stable, the precision is high, the deformation is not easy, and the risk of air leakage is greatly reduced.
  • FIG. 1 is an exploded perspective view of a flange of an automobile engine in the prior art.
  • FIG. 2 is a schematic structural view of an integrally cast flange of the present invention.
  • FIG. 3 is a partial cross-sectional structural view of the portion A in FIG. 2.
  • FIG. 1 is an exploded perspective view of a flange of an automobile engine in the prior art, which is composed of a original flange 101, a primary end cone and an original sensor nut 106.
  • the original end cone is composed of an end cone right portion 102 and an end cone left portion 103.
  • the end cone right portion 102 and the end cone left portion 103 are fixed by welding, the end cone right portion 102 and the end cone left portion 103 are structurally symmetrical, and the end cone right portion 102 is provided with a right semi-circular hole 104, the end cone
  • the left portion 103 is provided with a left semi-circular hole 105 that cooperates with the right semi-circular hole 104.
  • the right semi-circular hole 104 and the left semi-circular hole 105 cooperate to form a sensor mounting hole.
  • the original sensor nut 106 is welded and fixed on the sensor mounting hole, and the original end cone is welded. Installed on the original flange 101.
  • the flange of the automobile engine of this structure not only has many manufacturing processes, long working hours, high cost, waste of resources, but also the flange sealing surface after welding is easily deformed, and the flatness is 0.5 or more, resulting in poor sealing performance when connected to the engine. There is a risk of air leakage and there are potential safety hazards.
  • an integrated cast flange includes a flange 1, an end cone 2 and a sensor nut 3; the bottom end of the end cone 2 is provided with a transition portion 5, a transition portion 5 and an end cone 2
  • the end cone 2 is fixed to the flange 1 by the transition portion 5, the inner side surface of the transition portion 5 is flush with the inner side surface of the end cone 2, and the outer side surface of the transition portion 5 is circular arc shape, and the transition portion The upper and lower ends of the outer side surface of the fifth side are smoothly butted to the end cone 2 and the flange 1 respectively.
  • the connection strength between the flange 1 and the end cone 2 can be strengthened, and the thickness of the transition portion 5 is not limited.
  • the upper end of the transition portion 5 has a thickness of 2 mm, and the lower end of the transition portion 5 has a thickness of 2.5 mm;
  • the end cone 2 is provided with a sensor mounting hole, and the sensor nut 3 is fixed on the sensor mounting hole;
  • a feeding strip 4 is further disposed between the sensor nut 3 and the flange 1 , and the feeding strip 4 is fixed on the end cone 2 .
  • the upper end of the feeding strip 4 is fixedly connected to the sensor nut 3 , and the lower end of the feeding strip 4 is fixed.
  • the reinforcing strip 4 can enhance the connection strength between the flange 1 and the end cone 2, on the other hand, it can be transmitted
  • the nut 3 plays a role of feeding (the feeding is to compensate for the shrinkage, and the shrinking is a common casting defect). If there is no feeding strip 4, the connection between the sensor nut 3 and the end cone 2 is prone to shrinkage. The connection strength is reduced, and even when it is severe, the product is scrapped; the flange 1, the end cone 2 and the sensor nut 3 are integrally cast, and the processes such as forging, stamping, machining, and overall welding are eliminated. The process is reduced, the working time is shortened, the cost is reduced, and the resources are saved.
  • the flatness of the flange sealing surface is less than 0.2, which ensures the sealing property when connected with the engine, and the product is stable and high in precision (the dimensional tolerance of the cast product is the highest) It reaches within 0.1mm of the soil), is not easy to deform, and greatly reduces the risk of air leakage.
  • the manufacturing process of the integrated cast flange is as follows:
  • Shot wax wax is obtained by spraying wax at an ambient temperature of 22-26 ° C.
  • the wax temperature is 51-55 ° C
  • the pressure is 15-25 kg/cm 2
  • the waxing time is 40 s
  • the wax is taken out. Put it into the shaping tool for cooling;
  • Wax inspection Check the cooled wax to check whether the wax has structural defects, and require the wax to have no flash, no air bubbles, no damage, no flesh and other defects. If the wax has structural defects, then Return to step 1), otherwise, proceed to the next step;
  • Sand shell The ambient temperature is 22-26 °C, and the surface layer, the first layer, the second layer, the third layer, the fourth layer and the fifth layer are sequentially coated on the outside of the wax member, and finally the sealing is performed to obtain the wax component.
  • Dewaxing The sand shell containing the wax component is placed in a dewaxing kettle, dewaxed for more than eight minutes, and an empty sand shell is obtained.
  • the temperature in the autoclave of the dewaxing kettle is 140-170 ° C, and the pressure in the autoclave is 0.7. -0.8Mpa;
  • the flange manufactured by the invention is provided with a transition portion 5 between the flange 1 and the end cone 2, which can strengthen the connection between the flange 1 and the end cone 2 To improve the stability of the product; the flange manufactured by the invention has a feeding strip 4 between the sensor nut 3 and the flange 1 , and the feeding strip 4 can enhance the flange 1 and the end cone 2 on the one hand.
  • connection strength can complement the sensor nut 3, so that the connection between the sensor nut 3 and the end cone 2 is less likely to shrink, which improves the connection strength, greatly reduces the probability of breakage, and improves the service life of the product;
  • the flange manufactured by the invention is integrally cast, eliminating the steps of forging, stamping, machining, and overall welding. The manufacturing process is reduced, the working hours are shortened, the cost is reduced, and resources are saved. Since the welding is not required, the flatness of the flange sealing surface is eliminated. Below 0.2, the sealing performance when connecting with the engine is ensured, the product is stable, the precision is high, and it is not easy to be deformed, which greatly reduces the risk of air leakage.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Measuring Fluid Pressure (AREA)

Abstract

一种一体化铸造式法兰及其制造工艺，包括法兰盘（1）、端锥（2）和传感器螺母（3），端锥（2）底端设置有过渡部（5），过渡部（5）与端锥（2）为一体式结构，端锥（2）通过过渡部（5）固定在法兰盘（1）上，过渡部（5）的内侧面与端锥（2）的内侧面齐平，过渡部（5）的外侧面为圆弧形，且过渡部（5）的外侧面的上下两端分别与端锥（2）和法兰盘（1）平滑对接，端锥（2）上设置有传感器安装孔，传感器螺母（3）固定在传感器安装孔上，法兰盘（1）、端锥（2）和传感器螺母（3）采用一体化铸造而成，该法兰强度高，稳固性好，提高产品的使用寿命，与发动机连接时的密封性好，产品稳定，精度高，不易变形，大大降低了漏气风险，其制造工艺工序少，工时短，成本降低，节约资源。

Description

一种一体化铸造式法兰及其制造工艺 技术领域
本发明涉及汽车零部件技术领域，具体是一种一体化铸造式法兰及其制造工艺。
背景技术
汽车发动机上均设置有一个用于配气的法兰，此法兰还用于安装传感器。现有技术中，此法兰主要由法兰盘、端锥和传感器螺母组成，在生产过程中，需要首先通过锻造生产出法兰盘，通过冲压生产出端锥，通过车加工生产出传感器螺母，然后再将法兰盘、端锥和传感器螺母焊接为一个整体，不但制造工序繁多、工时长、成本高、浪费资源，而且焊接后的法兰密封面容易变形，平面度在0.5以上，导致在与发动机连接时密封性不良，有漏气风险，存在安全隐患。
发明内容
本发明的目的在于提供一种一体化铸造式法兰及其制造工艺，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：
一种一体化铸造式法兰，包括法兰盘、端锥和传感器螺母；所述端锥底端设置有过渡部，过渡部与端锥为一体式结构，端锥通过过渡部固定在法兰盘上，过渡部的内侧面与端锥的内侧面齐平，过渡部的外侧面为圆弧形，且过渡部的外侧面的上下两端分别与端锥和法兰盘平滑对接；所述端锥上设置有传感器安装孔，传感器螺母固定在传感器安装孔上；所述法兰盘、端锥和传感器螺母采用一体化铸造而成。
作为本发明进一步的方案：所述过渡部上端厚度为2mm，过渡部下端厚度为2.5mm。
作为本发明再进一步的方案：所述传感器螺母与法兰盘之间还设置有补缩条，补缩条固定在端锥上，补缩条的上端固定连接至传感器螺母，补缩条的下端固定连接至法兰盘。
所述一体化铸造式法兰的制造工艺，步骤如下：
1)射蜡：在环境温度为22-26℃下进行射蜡获得蜡件，射蜡温度为51-55℃，压力为15-25kg/cm2，射蜡时间为40s，将蜡件取出后放入定型工装内冷却；
2)蜡件检查：对冷却后的蜡件进行检查，以检查蜡件是否存在结构缺陷，若蜡件存在结构缺陷，则返回步骤1)，否则，进行下一步；
3)组数；
4)制砂壳：环境温度为22-26℃，在蜡件外依次包覆面层、一层、二层、三层、四层和五层，最后进行封浆，获得内含有蜡件的砂壳；
5)脱蜡：将内含有蜡件的砂壳放入脱蜡釜内，脱蜡处理八分钟以上，获得空砂壳，脱蜡釜的釜内温度为140-170℃，釜内压力为0.7-0.8Mpa；
6)浇铸：对空砂壳进行焙烧处理，焙烧温度为1120-1140℃，焙烧处理完毕后，浇铸1660-1670℃的钢水，冷却成型；
7)后清理：依次经过震壳、吊抛、切割、磨浇口、泡清砂剂、喷砂、毛坯初检、精修、抛不锈钢丸、毛坯整形、毛坯终检，获得毛坯；
8)机加工：对毛坯的法兰面及传感器螺母进行机加工，获得成品；
9)成品检验：对成品的外观、位置度及尺寸进行检验。
与现有技术相比，本发明的有益效果是：
1、本发明制造的法兰，其法兰盘与端锥之间设置有过渡部，能够加强法兰盘与端锥的连接强度，提高产品的稳固性；
2.本发明制造的法兰，其传感器螺母与法兰盘之间设置有补缩条，补缩条一方面能够增强法兰盘与端锥的连接强度，另一方面能够对传感器螺母起到补缩作用，使传感器螺母与端锥连接处不易出现缩松，提高了连接强度，大大降低了断裂几率，提高产品的使用寿命；
3、本发明法兰的制造工艺，取消了锻造、冲压、车加工、整体焊接等工序，制造工序减少、工时缩短、成本降低，节约资源，由于无需焊接，法兰密封面的平面度在0.2以下，保证了与发动机连接时的密封性，产品稳定，精度高，不易变形，大大降低了漏气风险。
附图说明
图1为现有技术中汽车发动机处法兰的分解示意图。
图2为本发明一体化铸造式法兰的结构示意图。
图3为图2中A处局部剖视结构示意图。
图中：101-原法兰盘、102-端锥右部、103-端锥左部、104-右半圆孔、105-左半圆孔、106-原传感器螺母、1-法兰盘、2-端锥、3-传感器螺母、4-补缩条、5-过渡部。
具体实施方式
下面结合具体实施方式对本发明的技术方案作进一步详细地说明。
图1为现有技术中汽车发动机处法兰的分解示意图，由原法兰盘101、原端锥和原传感器螺母106组成，所述原端锥由端锥右部102和端锥左部103拼接而成，端锥右部102与端锥左部103之间通过焊接固定，端锥右部102与端锥左部103结构对称，端锥右部102上设置有右半圆孔104，端锥左部103上设置有与右半圆孔104相配合的左半圆孔105，右半圆孔104与左半圆孔105配合组成传感器安装孔，原传感器螺母106焊接固定在传感器安装孔上，原端锥焊接安装在原法兰盘101上。这种结构的汽车发动机处法兰，不但制造工序繁多、工时长、成本高、浪费资源，而且焊接后的法兰密封面容易变形，平面度在0.5以上，导致在与发动机连接时密封性不良，有漏气风险，存在安全隐患。
请参阅图2-3，一种一体化铸造式法兰，包括法兰盘1、端锥2和传感器螺母3；所述端锥2底端设置有过渡部5，过渡部5与端锥2为一体式结构，端锥2通过过渡部5固定在法兰盘1上，过渡部5的内侧面与端锥2的内侧面齐平，过渡部5的外侧面为圆弧形，且过渡部5的外侧面的上下两端分别与端锥2和法兰盘1平滑对接，通过设置过渡部5，能够加强法兰盘1与端锥2的连接强度，过渡部5的厚度不加限制，本实施例中，优选的，所述过渡部5上端厚度为2mm，过渡部5下端厚度为2.5mm；所述端锥2上设置有传感器安装孔，传感器螺母3固定在传感器安装孔上；所述传感器螺母3与法兰盘1之间还设置有补缩条4，补缩条4固定在端锥2上，补缩条4的上端固定连接至传感器螺母3，补缩条4的下端固定连接至法兰盘1，补缩条4一方面能够增强法兰盘1与端锥2的连接强度，另一方面能够对传感器螺母3起到补缩作用(补缩就是弥补缩松，缩松是一种常见的铸造缺陷)，如果没有补缩条4，传感器螺母3与端锥2连接处就容易出现缩松，使连接强度降低，严重时甚至出现断裂，导致产品报废；所述法兰盘1、端锥2和传感器螺母3采用一体化铸造而成，取消了锻造、冲压、车加工、整体焊接等工序，制造工序减少、工时缩短、成本降低，节约资源，由于无需焊接，法兰密封面的平面度在0.2以下，保证了与发动机连接时的密封性，产品稳定，精度高(铸造产品的尺寸公差最高能达到土0.1mm以内)，不易变形，大大降低了漏气风险。
所述一体化铸造式法兰的制造工艺，步骤如下：
1)射蜡：在环境温度为22-26℃下进行射蜡获得蜡件，射蜡温度为51-55℃，压力为15-25kg/cm2，射蜡时间为40s，将蜡件取出后放入定型工装内冷却；
2)蜡件检查：对冷却后的蜡件进行检查，以检查蜡件是否存在结构缺陷，要求蜡件无飞边、无气泡、无破损、无多肉等缺陷，若蜡件存在结构缺陷，则返回步骤1)，否则，进行下一步；
3)组数：要求无缝隙、无蜡滴；
4)制砂壳：环境温度为22-26℃，在蜡件外依次包覆面层、一层、二层、三层、四层和五层，最后进行封浆，获得内含有蜡件的砂壳；
5)脱蜡：将内含有蜡件的砂壳放入脱蜡釜内，脱蜡处理八分钟以上，获得空砂壳，脱蜡釜的釜内温度为140-170℃，釜内压力为0.7-0.8Mpa；
6)浇铸：对空砂壳进行焙烧处理，焙烧温度为1120-1140℃，焙烧处理完毕后，浇铸1660-1670℃的钢水，冷却成型；
7)后清理：依次经过震壳、吊抛、切割、磨浇口、泡清砂剂、喷砂、毛坯初检、精修、抛不锈钢丸、毛坯整形、毛坯终检，获得毛坯；
8)机加工：对毛坯的法兰面及传感器螺母进行机加工，获得成品；
9)成品检验：对成品的外观、位置度及尺寸进行检验。
本发明制造的法兰，其法兰盘1与端锥2之间设置有过渡部5，能够加强法兰盘1与端锥2的连接强 度，提高产品的稳固性；本发明制造的法兰，其传感器螺母3与法兰盘1之间设置有补缩条4，补缩条4一方面能够增强法兰盘1与端锥2的连接强度，另一方面能够对传感器螺母3起到补缩作用，使传感器螺母3与端锥2连接处不易出现缩松，提高了连接强度，大大降低了断裂几率，提高产品的使用寿命；本发明制造的法兰采用一体化铸造而成，取消了锻造、冲压、车加工、整体焊接等工序，制造工序减少、工时缩短、成本降低，节约资源，由于无需焊接，法兰密封面的平面度在0.2以下，保证了与发动机连接时的密封性，产品稳定，精度高，不易变形，大大降低了漏气风险。
上面对本发明的较佳实施方式作了详细说明，但是本发明并不限于上述实施方式，在本领域的普通技术人员所具备的知识范围内，还可以在不脱离本发明宗旨的前提下作出各种变化。

Claims (4)

  1. 一种一体化铸造式法兰，其特征在于，包括法兰盘(1)、端锥(2)和传感器螺母(3)；所述端锥(2)底端设置有过渡部(5)，过渡部(5)与端锥(2)为一体式结构，端锥(2)通过过渡部(5)固定在法兰盘(1)上，过渡部(5)的内侧面与端锥(2)的内侧面齐平，过渡部(5)的外侧面为圆弧形，且过渡部(5)的外侧面的上下两端分别与端锥(2)和法兰盘(1)平滑对接；所述端锥(2)上设置有传感器安装孔，传感器螺母(3)固定在传感器安装孔上；所述法兰盘(1)、端锥(2)和传感器螺母(3)采用一体化铸造而成。
  2. 根据权利要求1所述的一体化铸造式法兰，其特征在于，所述过渡部(5)上端厚度为2mm，过渡部(5)下端厚度为2.5mm。
  3. 根据权利要求2所述的一体化铸造式法兰，其特征在于，所述传感器螺母(3)与法兰盘(1)之间还设置有补缩条(4)，补缩条(4)固定在端锥(2)上，补缩条(4)的上端固定连接至传感器螺母(3)，补缩条(4)的下端固定连接至法兰盘(1)。
  4. 一种如权利要求1-3任一所述的一体化铸造式法兰的制造工艺，其特征在于，步骤如下：
    1)射蜡：在环境温度为22-26℃下进行射蜡获得蜡件，射蜡温度为51-55℃，压力为15-25kg/cm2，射蜡时间为40s，将蜡件取出后放入定型工装内冷却；
    2)蜡件检查：对冷却后的蜡件进行检查，以检查蜡件是否存在结构缺陷，若蜡件存在结构缺陷，则返回步骤1)，否则，进行下一步；
    3)组数；
    4)制砂壳：环境温度为22-26℃，在蜡件外依次包覆面层、一层、二层、三层、四层和五层，最后进行封浆，获得内含有蜡件的砂壳；
    5)脱蜡：将内含有蜡件的砂壳放入脱蜡釜内，脱蜡处理八分钟以上，获得空砂壳，脱蜡釜的釜内温度为140-170℃，釜内压力为0.7-0.8Mpa；
    6)浇铸：对空砂壳进行焙烧处理，焙烧温度为1120-1140℃，焙烧处理完毕后，浇铸1660-1670℃的钢水，冷却成型；
    7)后清理：依次经过震壳、吊抛、切割、磨浇口、泡清砂剂、喷砂、毛坯初检、精修、抛不锈钢丸、毛坯整形、毛坯终检，获得毛坯；
    8)机加工：对毛坯的法兰面及传感器螺母进行机加工，获得成品；
    9)成品检验：对成品的外观、位置度及尺寸进行检验。
PCT/CN2016/109078 2016-12-08 2016-12-08 一种一体化铸造式法兰及其制造工艺 WO2018103049A1 (zh)

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